Weld tracking systems

ABSTRACT

Described herein are examples of weld tracking systems. In some examples, a weld tracking system include weld tracking sensors configured to allow the weld tracking system to track a position and/or orientation of a welding-type tool, and/or an arc generated by the welding-type tool. In some examples, the weld tracking system evaluates certain welding technique and/or welding operation parameters based on the tracked position(s) and/or orientation(s), and/or offers corrective feedback. In some examples, one or more calibrations may be performed to aid in evaluation of the welding technique and/or welding operation parameters.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of, and priority to, U.S.Provisional Patent Application No. 63/149,563, entitled “WELD TRACKINGSYSTEMS,” filed Feb. 15, 2021, the entire contents of which are herebyincorporated by reference.

TECHNICAL FIELD

The present disclosure generally relates to weld tracking systems.

BACKGROUND

Weld tracking refers to the practice of tracking how, when, and where awelding-type operation occurs. Weld tracking systems are used toautomate as much of the practice as possible. The data captured by weldtracking systems can be used for quality assurance, operator training,and/or analytics.

Limitations and disadvantages of conventional and traditional approacheswill become apparent to one of skill in the art, through comparison ofsuch systems with the present disclosure as set forth in the remainderof the present application with reference to the drawings.

BRIEF SUMMARY

The present disclosure is directed to helmet based weld trackingsystems, substantially as illustrated by and/or described in connectionwith at least one of the figures, and as set forth more completely inthe claims.

These and other advantages, aspects and novel features of the presentdisclosure, as well as details of an illustrated example thereof, willbe more fully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of a weld tracking system, in accordance withaspects of this disclosure.

FIGS. 2a-2b show example front and side views of a welding helmet thatmay be used in the weld tracking system of FIG. 1, in accordance withaspects of this disclosure.

FIG. 3 is a block diagram showing example components and connections ofthe weld tracking system, in accordance with aspects of this disclosure.

FIG. 4 is a flow diagram illustrating an example operation of a weldtracking process, in accordance with aspects of this disclosure.

FIGS. 5a-5d show an example joint calibration process, as well asexamples of how the joint may be highlighted on a display screenfollowing the joint calibration process, in accordance with aspects ofthis disclosure.

FIG. 6 shows an example of feedback presented to an operator on adisplay screen, in accordance with aspects of this disclosure.

FIG. 7 shows example relationships between a reference point, awelding-type tool, and the welding helmet of FIG. 2a , in accordancewith aspects of this disclosure.

The figures are not necessarily to scale. Where appropriate, the same orsimilar reference numerals are used in the figures to refer to similaror identical elements.

DETAILED DESCRIPTION

Some examples of the present disclosure relate to weld tracking systemsthat may be implemented entirely in (and/or on) a welding helmet. Insome examples, having such a helmet based weld tracking system mayprovide a convenient, compact, and portable means of weld tracking, thatis not restricted to the confines of a fixed weld tracking system.

In some examples, a helmet based weld tracking system may track its ownposition and/or orientation relative to a reference point in a weldingenvironment, as well as the position and/or orientation of awelding-type tool and/or arc relative to the helmet. In this way, thehelmet based weld tracking system can differentiate between movement ofthe helmet and movement of the tool and/or arc. By tracking movement ofthe tool and/or arc the weld tracking system can analyze the weldingtechnique of an operator, the location(s) of the welding operation(s),and/or the sequence of welding operations. In cases where the weldtracking data, welding technique, welding location, and/or weld sequencedeviates from what is expected, the helmet based weld tracking systemsmay offer corrective feedback, change welding parameters to compensate,and/or disable welding entirely. In some examples, the weld trackingsystem may be calibrated using the welding-type tool (and/or other tool)to provide more robust performance.

Some examples of the present disclosure relate to a weld trackingsystem, comprising: a sensor system configured to capture sensor datapertaining to a welding environment; and control circuitry configuredto: track a torch position of a welding-type torch based on the sensordata, track a tool position of a calibration tool based on the sensordata, identify a first endpoint based on the tool position when thecalibration tool is activated, identify a second endpoint based on thetorch position when welding is initiated via the welding-type torch, andidentify a weld path based on the first endpoint and the secondendpoint.

In some examples, the control circuitry is configured to identify theweld path as comprising a path between the first endpoint and the secondendpoint. In some examples, the control circuitry is configured toidentify the weld path as comprising the shortest path between the firstendpoint and the second endpoint. In some examples, the controlcircuitry is configured to identify the weld path as comprising a linebetween the first endpoint and the second endpoint.

In some examples, the calibration tool comprises the welding-type torch.In some examples, welding is initiated via the welding-type torch whenthe welding-type torch performs a tack weld. In some examples, thecontrol circuitry is configured to identify the second welding pointbased on the torch position when welding is initiated via thewelding-type torch for less than one second.

In some examples, the control circuitry is configured to: identify anintermediate point based on the tool position when the calibration toolis activated or the torch position when welding is initiated via thewelding-type torch, and identify the weld path based on the firstendpoint, the intermediate point, and the second endpoint. In someexamples, the control circuitry is configured to identify the weld pathas comprising a path between the first endpoint and the second endpointthat also intersects the intermediate point. In some examples, the weldtracking system further comprises a display screen configured to displaya representation of the weld path.

Some examples of the present disclosure relate to a weld trackingsystem, comprising: a sensor system configured to capture sensor datapertaining to a welding environment; and processing circuitry; andmemory circuitry comprising machine readable instructions which, whenexecuted by the processing circuitry, cause the processing circuitry to:track a torch position of a welding-type torch based on the sensor data,track a tool position of a calibration tool based on the sensor data,identify a first endpoint based on the tool position when thecalibration tool is activated, identify a second endpoint based on thetorch position when welding is initiated via the welding-type torch, andidentify a weld path based on the first endpoint and the secondendpoint.

In some examples, the memory circuitry comprises machine readableinstructions which, when executed by the processing circuitry, cause theprocessing circuitry to identify the weld path as comprising a pathbetween the first endpoint and the second endpoint. In some examples,the memory circuitry comprises machine readable instructions which, whenexecuted by the processing circuitry, cause the processing circuitry toidentify the weld path as comprising the shortest path between the firstendpoint and the second endpoint. In some examples, the memory circuitrycomprises machine readable instructions which, when executed by theprocessing circuitry, cause the processing circuitry to identify theweld path as comprising a line between the first endpoint and the secondendpoint.

In some examples, the calibration tool comprises the welding-type torch.In some examples, welding is initiated via the welding-type torch whenthe welding-type torch performs a tack weld. In some examples, thememory circuitry comprises machine readable instructions which, whenexecuted by the processing circuitry, cause the processing circuitry toidentify the second welding point based on the torch position whenwelding is initiated via the welding-type torch for less than onesecond.

In some examples, the memory circuitry comprises machine readableinstructions which, when executed by the processing circuitry, cause theprocessing circuitry to: identify an intermediate point based on thetool position when the calibration tool is activated or the torchposition when welding is initiated via the welding-type torch, andidentify the weld path based on the first endpoint, the intermediatepoint, and the second endpoint. In some examples, the memory circuitrycomprises machine readable instructions which, when executed by theprocessing circuitry, cause the processing circuitry to identify theweld path as comprising a path between the first endpoint and the secondendpoint that also intersects the intermediate point. In some examples,the weld tracking system further comprises a display screen configuredto display a representation of the weld path.

FIG. 1 shows an example of a weld tracking system 100. As shown, theweld tracking system 100 includes weld tracking sensors 102 fixed withina welding environment. In some examples, the environment fixed weldtracking sensors 102 may be used to supplement and/or replace helmetbased weld tracking sensors. In some examples, the weld tracking sensors102 are configured to track a welding-type operation performed withinthe welding environment, such as, for example, the welding-typeoperation being performed by the welding operator 104 on a workpiece 106sitting on a welding bench 108 in the example of FIG. 1.

In the example of FIG. 1, the weld tracking sensors 102 are stationaryand/or mounted to fixtures (e.g., wall(s), pillar(s), ceiling, etc.). Insome examples, the weld tracking sensors 102 may comprise camerasensors, optical sensors, infra-red (IR) sensors, thermal sensors,acoustic sensors, ultrasonic sensors, electromagnetic sensors, and/orother appropriate types of sensors. While two environment fixed weldtracking sensors 102 are shown in the example of FIG. 1, in someexamples, more or fewer weld tracking sensors 102 may be used. In someexamples, at least four environment fixed weld tracking sensors 102 maybe used, placed around the environment in such a way to ensure line ofsight visibility to the welding-type operation. In some examples, theweld tracking sensors 102 may include processing circuitry configured toprocess data captured by the weld tracking sensors 102, and/orcommunication circuitry configured to transmit the captured data toother components of the weld tracking system 100.

In some examples, the weld tracking sensors 102 may be configured totrack the welding-type operation by tracking (and/or capturing datarelating to) the position and/or orientation of a welding-type tool 110and/or an arc 112 generated by the welding-type tool 110. In someexamples, the welding-type tool 110 may be considered part of the weldtracking system 100. In the example of FIG. 1, the operator 104 is usingthe welding-type tool 110 to perform a welding-type operation on aworkpiece 106, via the arc 112. While not shown in the example of FIG. 1for the sake of simplicity, in some examples, the workpiece(s) 106 maybe secured and/or fixed in place (e.g., relative to the welding bench108) by a clamp and/or other welding fixture(s). In some examples, theweld tracking sensors 102 may be further configured to track (and/orcapture data relating to) the workpiece(s) 106.

While depicted in FIG. 1 as a welding torch or gun configured for gasmetal arc welding (GMAW), in some examples, the welding-type tool 110may instead be a different welding-type tool 110. For example, thewelding-type tool 110 may be an electrode holder (i.e., stinger)configured for shielded metal arc welding (SMAW), a torch and/or fillerrod configured for gas tungsten arc welding (GTAW), a welding gunconfigured for flux-cored arc welding (FCAW), and/or a plasma cutter. Insome examples, the welding-type tool 110 may be a mock welding-typetool, and/or be configured for mock (as opposed to live) welding-typeoperations, such as for (e.g., virtual/augmented reality) weld training.

In the example of FIG. 1, the welding-type tool 110 includes markers 114attached to a handle, neck, and nozzle of the welding-type tool 110. Insome examples, the markers 114 may assist the weld tracking sensors 102and/or weld tracking system 100 in tracking the position and/ororientation of the welding-type tool 110. For example, the markers 114may be easily recognizable by the weld tracking system 100 in (e.g.,image) data captured by the weld tracking sensors 102. Thus, the markers114 may assist in identifying and/or recognizing the welding-type tool110.

In some examples, the markers 114 may assist in identifying and/orrecognizing particular portions of the welding-type tool 110. Forexample, the markers 114 may define (and/or may be calibrated to define)a recognizable and/or unique geometric configuration (and/or rigidbody). In some examples, this geometric configuration (and/or rigidbody) can be correlated (e.g., in memory) with a known (e.g., stored inmemory) structural configuration and/or model of the welding-type tool110. Thus, by identifying and/or tracking the particular geometricconfiguration of markers 114, the weld tracking system 100 may be ableto identify and/or track the structural configuration of thewelding-type tool 110; including particular portions (e.g., nozzle,neck, handle, etc.) of the structural configuration.

In some examples, the welding-type tool 110 may include no markers 114.In such examples, the weld tracking system 100 may instead use objectrecognition, computer vision, and/or other image processing techniquesto identify, recognize, and/or track the welding-type tool 110.

In some examples, the welding-type tool 110 may include at least threemarkers 114 fixed to the welding-type tool 110 relative to one anotherin a single plane, and a fourth marker 114 fixed to the welding-typetool 110 in a different (e.g., adjacent) plane, to define a rigid body.While a certain number of markers 114 are shown in the example of FIG. 1attached to the handle, neck, and nozzle of the welding-type tool 110for the purposes of illustration, in some examples more or fewer markers114 may be attached to the handle, neck, nozzle, and/or other portionsof the welding-type tool 110.

In some examples, one or more of the markers 114 may be permanentlyaffixed to the welding-type tool 110 (e.g., via welding, molding,screws, etc.). In some examples, one or more of the markers 114 may beremovably attached to the welding-type tool 110 in such a way to allowrelatively easy removal and/or reattachment without the use of tools,such as, for example, through the use of adhesives, straps, hook andloop fasteners, magnets, clamps, and/or other appropriate mechanisms. Insome examples, the welding-type tool 110 may include attachment features(e.g., adhesives, straps, hook and loop fasteners, magnets, etc.)configured to mate with complementary attachment features of the markers114, to removably attach the markers 114 to the welding-type tool 110.

In some examples, one or more of the markers 114 may be passive markers114 that require no electrical power to operate, such as, for example,reflective markers 114 and/or pattern markers 114. In some examples, oneor more of the markers 114 may be active markers 114 that areelectrically powered, such as, for example, IR light emitting diodes(LEDs), and/or fiducial markers (e.g., IR light sources partiallycovered by light blocking patterns). In some examples where the markers114 are active markers 114, the attachment features discussed above mayhelp to conduct electrical power to the markers 114.

In some examples where the markers 114 are active markers 114, themarkers 114 may be continuously powered on, or only powered on atcertain times. For example, welding-type tool 110 may include one ormore sensors (e.g., inertial sensor(s), accelerometer(s), gyroscope(s),magnetic sensor(s), optical sensor(s), current/voltage sensor(s), etc.)and/or control circuitry configured to power on/off the markers 114based on the detection(s)/measurement(s) of the sensor(s). For example,the control circuitry may be configured to turn on the markers 114 whenthe sensor(s) detect movement, and turn off the markers 114 after acertain period of time with no motion detected. As another example, thecontrol circuitry may be configured to turn on the markers 114 when thesensor(s) detect a threshold amount of light (e.g., from the arc 112), athreshold amount of current/voltage being supplied to the welding-typetool 110, and/or when a welding-type operation is initiated by thewelding-type tool 110 (e.g., via activation of a trigger of thewelding-type tool 110). In some examples, the welding-type tool 110 maybe in communication with one or more other devices of the weld trackingsystem 100, and may turn on/off the markers 114 based on thecommunication signal(s).

In some examples where one or more of the markers 114 are active markers114, the welding-type tool 110 may include a separate power source(e.g., battery) to provide power to the marker(s) 114. In some examples,the separate power source may include one or more solar panelsconfigured to capture light from the arc 112. In some examples where oneor more of the markers 114 are active markers 114, power may be providedfrom mains power, and a separate power cord (not shown) may be used toroute the power. In some examples where one or more of the markers 114are active markers 114, power may be inductively supplied via weldingcurrent flowing through the welding-type tool 110. In some exampleswhere one or more of the markers 114 are active markers 114,welding-type power supplied to the welding-type tool 110 may be used topower the markers 114.

In the example of FIG. 1, the welding-type tool 110 is connected towelding-type equipment 116 configured to provide welding-type powerand/or consumables to the welding-type tool 110. In some examples, thewelding-type tool 110 may transmit one or more signals to thewelding-type equipment 116 (and/or other components of the weld trackingsystem 100) when activated, so that the welding-type equipment knows toprovide welding-type power and/or consumables to the welding-type tool110. In some examples, the welding-type equipment 116 may be consideredpart of the weld tracking system 100. In some examples, the welding-typeequipment 116 may be omitted, or may be mock and/or simulatedwelding-type equipment 116, such as may be used for training, simulated,and/or mock welding-type operations.

In the example of FIG. 1, the welding-type equipment 106 comprises awelding-type power supply 118, wire feeder 120, and gas supply 122. Insome examples, the wire feeder 120 may be configured to feed wire to thewelding-type tool 110. In some examples, the gas supply 122 may beconfigured to route shielding gas to the welding-type tool 110.

In the example of FIG. 1, the power supply 118 includes powercommunication circuitry 124, power control circuitry 126, and powerconversion circuitry 128 interconnected with one another. In someexamples, the power conversion circuitry 128 may be configured toreceive input power (e.g., from a generator, a battery, mains power,etc.) and convert the input power to welding-type output power, such asmight be suitable for use by the welding-type tool 110 for welding-typeoperations. In some examples, the power control circuitry 126 may beconfigured to control operation of the communication circuitry 124,power conversion circuitry 128, wire feeder 120, and/or gas supply 122(e.g. via one or more control signals) in accordance with one or morewelding parameters.

In the example of FIG. 1, the welding-type equipment 116 furtherincludes an operator interface 130. In some examples, the operatorinterface 130 may comprise one or more display screens, touch screens,knobs, buttons, levers, switches, microphones, speakers, lights, and/orother mechanisms through which an operator 104 may provide input to,and/or receive output from, the welding-type equipment. For example, anoperator 104 may use the operator interface 130 to input one or morewelding parameters (e.g., target voltage, current, wire feed speed,wire/filler type, wire/filler diameter, gas type, gas flow rate,welding-type process, material type of workpiece 106, position ofwelding-type process, etc.). As another example, the operator 104 mayuse the operator interface 130 to view and/or otherwise understand thecurrent welding parameters of the welding-type equipment 116.

While shown as part of the power supply 118 in FIG. 1, in some examples,the operator interface 130, power control circuitry 126, and/or powercommunication circuitry 124 (and/or some other control/communicationcircuitry) may be part of the wire feeder 120 and/or gas supply 122. Insome examples, the power communication circuitry 124 may be configuredto facilitate communication with the welding-type tool 110 and/or awelding helmet 200 worn by the operator. In some examples, the powercommunication circuitry 124 may be configured to facilitatecommunication with a computing system 150 and/or one or more othercomputing systems (e.g., remote server(s)).

In the example of FIG. 1, the weld tracking system 100 further includesa computing system 150. While shown as a desktop computer in the exampleof FIG. 1, in some examples, the computing system 150 may instead besome other appropriate computational apparatus, such as, for example, alaptop computer, a tablet computer, and/or a web server. Though shown asbeing physically connected to the welding-type equipment 116 via a wirecable, in some examples, the computing system 150 may instead be inwireless communication with the welding-type equipment 116 (and/orwelding helmet 200). In some examples, the computing system 150 may beimplemented via the welding-type equipment 116 and/or welding helmet200.

In some examples, the computing system 150 may implement a weldmonitoring system configured to monitor, record, and/or analyze datacaptured and/or generated by the weld tracking system 100 and/or otherweld tracking systems. For example, the computing system 150 maymonitor, record, and/or analyze welding parameters of the welding-typeequipment 116 during welding-type operations. As another example, thecomputing system 150 may monitor, record, and/or analyze informationabout the welding technique of the welding operator 104, location(s) ofwelds, and/or sequence(s) of welds during welding-type operations. Insome examples, the computing system 150 may monitor, record, and/oranalyze welding-type operation data for multiple welding-type operationsand/or welding operators 104 when implementing the weld monitoringsystem. In some examples, the computing system 150 may additionallystore and/or output data relating to the planned, expected, target,and/or exemplary job, work instructions, welding-type operation, weldingparameters, welding location(s), weld sequence(s), and/or weldingtechnique parameters when implementing the weld monitoring system. Insome examples, the computing system 150 may be in communication with oneor more other computing systems, which may additionally, oralternatively, implement the weld monitoring system.

In some examples, the computing system 150 may be configured to receive,process, and/or analyze data captured by the weld tracking sensors 102to perform weld tracking operations. For example, the computing system150 may analyze data received from the weld tracking sensors 102 totrack the position and/or location of the welding-type tool 110, arc112, and/or workpiece 106 in six degrees of freedom (DOF) (e.g., x, y, zcoordinates and yaw, pitch, roll angles).

In some examples, the computing system 150 may determine weldingtechnique parameters (e.g., contact to work distance, travel speed,travel angle, work angle, etc.) based on the tracked positions and/orlocations of the welding-type tool 110, arc 112, and/or workpiece 106.For example, the computing system 150 may identify a position of (e.g.,a nozzle of) the welding-type tool 110 and visible positions of the arc112 closest and farthest from the (e.g., nozzle of the) welding-typetool 110, and estimate the contact to work distance as beingapproximately equal to the distance between the two positions (e.g., thevisible length of the arc 112). As another example, the computing system150 may identify a position of (e.g., a nozzle of) the welding-type tool110 and a position of the workpiece 116, and estimate the contact towork distance as being approximately equal to the distance between thetwo positions.

In some examples, the computing system 150 may additionally, oralternatively, determine one or more welding operation parameter basedon the tracked positions and/or locations of the welding-type tool 110,arc 112, and/or workpiece 106. In some examples, welding operationparameters may include welding location information (e.g., location ofweld produced by arc 112 and/or welding-type operation) and/or weldsequence information (e.g., present welding location relative to orderedsequence of one or more prior welding locations). For example, thecomputing system 150 may identify a position of (e.g., a nozzle of) thewelding-type tool 110 and positions of the arc 112 closest and farthestfrom the (e.g., nozzle of the) welding-type tool 110, and estimate thewelding location(s) to be at the point of the arc 112 farthest from the(e.g., nozzle of the) welding-type tool 110. As another example, thecomputing system 150 may identify where the arc 112 intersects theworkpiece 106, and estimate the welding location(s) to be at thepoint(s) of intersection. As another example, the computing system 150may use both the intersection point and the farthest point from the(e.g., nozzle of the) welding-type tool 110 together to estimate thewelding location(s).

In some examples, the computing system 150 may additionally, oralternatively, determine one or more welding sequences based on thedetermined welding location(s) and an ordered sequence of one or moreprior welding locations. For example, the computing system 150 mayidentify the welding location of the current weld using the trackedpositions and/or locations of the welding-type tool 110, arc 112, and/orworkpiece 106 (as discussed above). The computing system 150 maythereafter identify the current welding location(s) as being the latestiteration in a sequence of welds that previously included an orderedsequence of one or more previous welds at one or more previouslyrecorded welding locations. In some examples, the computing system 150may identify an order of the sequence of welds based on timestampsassociated with the one or more previously (and/or currently) recordedwelding locations.

In some examples, the computing system 150 may provide feedback to awelding operator 104. For example, the computing system 150 may providefeedback as to whether their welding technique is within a thresholdrange of what is expected, and/or whether their technique needs to beadjusted. As another example, the computing system 150 may providefeedback as to whether the welding location is within a threshold rangeof what is expected, and/or needs to be adjusted. As another example,the computing system 150 may provide feedback as to whether the weldingsequence is the same as what is expected, and/or needs to be adjusted.In some examples, the feedback may be provided to the operator 104 via auser interface (UI) 151 of the computing system 150 and/or the helmetI/O device(s) 208 of the welding helmet 200 (discussed further belowwith respect to FIGS. 2a-2b ).

In the example of FIG. 1, the UI 151 of the computing system 150includes input devices (e.g., a keyboard and mouse) as well as outputdevices (e.g., a display screen and speakers). In some examples, theinput devices may include, for example, one or more keyboards, mice,touch screens, remote controls, and/or other suitable input devices. Insome examples, the output devices may include, for example, one or moredisplay screens, speakers, and/or other suitable output devices. In someexamples, the UI 151 may include one or more (e.g., CD, DVD) drives,(e.g., USB) ports, and/or other devices through which the computingsystem 150 may interface with local storage devices. While not shown forthe sake of simplicity and clarity, in some examples, the UI 151 iselectrically connected and/or in electrical communication with thecomputing system 150. In some examples, the UI 151 may be consideredpart of the weld tracking system 100.

In the example of FIG. 1, the weld tracking system 100 further includesa calibration tool 132. In some examples, the calibration tool 132 maybe used to help calibrate the weld tracking system 100 via a calibrationprocedure. For example, the calibration tool 132 may be used to help theweld tracking system 100 understand the 6 DOF position and/ororientation of the workpiece(s) 106 (which are typically stationary). Asshown, the calibration tool 132 is a pen style pointer. In someexamples, the calibration tool 132 may be differently configured. Insome examples, the welding-type tool 110 may be used as the calibrationtool 132.

FIG. 5a shows an enlarged view of the calibration tool 132. As shown,the calibration tool 132 includes pattern markers 114 to help the weldtracking sensors 102 and/or tracking system 100 identify, recognize,and/or track the position of the calibration tool 132, (e.g., similar tothat described above with respect to the welding-type tool 110). In someexamples, the markers 114 may be active or passive markers 114, and/ormay be powered on/off (e.g., similar to that which is described abovewith respect to the welding-type tool 110). In some examples, thecalibration tool 132 may include no markers 114, and the weld trackingsystem 100 may instead use object recognition, computer vision, and/orother image processing techniques to identify, recognize, and/or trackthe calibration tool 132.

In the example of FIG. 5a , the calibration tool 132 further includesinputs 134. In some examples, the inputs 134 may be buttons, switches,dials, keys, knobs, and/or other appropriate user interface inputmechanisms. While two inputs 134 are shown in the example of FIG. 5a ,in some examples, the calibration tool 132 may include more or fewerinputs 134. In some examples, the calibration tool 132 may includecommunication circuitry configured to send one or more signals to theweld tracking sensors 102, welding-type equipment 116, computing system150, welding helmet 200, and/or other components of the weld trackingsystem 100 when an input 134 is activated.

In the example of FIG. 1, the weld tracking system 100 further includesa welding helmet 200 worn by the welding operator 104. In some examples,the welding helmet 200 may implement portions of the weld trackingsystem 100, such as, for example, the weld tracking sensors 102 and/orthe computing system 150. In some examples, the welding helmet 200 maycomprise a convenient, compact, portable, self-contained, and/orindependently operable weld tracking system unto itself. In someexamples, the independence, portability, and/or capabilities of thewelding helmet 200 may allow for weld tracking both without the othercomponents of the weld tracking system 100 and/or outside of therelatively small footprint and/or range of the fixed weld trackingsensors 102.

While a welding helmet 200 may be used as a self-contained, portable,weld tracking system, in some examples, other wearable items may be alsoused in place of, or in addition to, a welding helmet 200. For example,a hat, vest, goggles, sleeve, wristband, collar, pendant, and/or otherwearable item may be used in place of, or in addition to, a weldinghelmet 200 as a self-contained, portable, weld tracking system. Thatsaid, there are obvious advantages to using the welding helmet 200 asthe wearable item (e.g., familiarity of operator 114, likelihood ofwelding-type tool 110 and/or welding-operation being visible, etc.).

FIGS. 2a-2b show enlarged front and side view of an example weldinghelmet 200. As shown, the smart welding helmet 200 comprises a helmetshell 202 attached to a suspension 204. As shown, the suspension 204comprises several straps and/or bands configured to wrap around the headof an operator 102. The straps are connected to one another and to thehelmet shell 202 at least at two side attachment points on either sideof the head of the operator 102. In some examples, the smart helmet 200may be configured to rotate and/or pivot about the side attachmentpoints to transition between raised and lowered positions. In someexamples where other wearable items are used instead of, or in additionto, the welding helmet 200, the wearable items may have a retentionmechanism (e.g., similar to the suspension 204) to keep the wearablesecurely attached to the operator 102 when worn (e.g., one or moreclips, sleeves, chains, bands, pins/holders, etc.).

In the examples of FIGS. 2a-2b , the welding helmet 200 also includes alens assembly 206 fixed to (and/or integrated into) a front portion ofthe helmet shell 202 at approximately eye level. In some examples, thelens assembly 206 may include a cover lens, an auto-darkening filter(ADF), and/or a display screen. In some examples, the cover lens may be(e.g., partially or fully) transparent and/or configured to allow anoperator 104 to see through the cover lens and/or view the surroundingenvironment.

In some examples, the ADF comprises a lens (and/or lens cartridge) witha transparency that varies based on one or more signals provided by aphotodiode sensor (and/or other sensor(s)). In some examples, thephotodiode sensor (and/or other sensor(s)) may be configured to detectlight in front of and/or around the welding helmet 200 and send one ormore signals to the ADF when the detected light is above a thresholdintensity (e.g., indicating the light is from the arc 112). In someexamples, the signal(s) to the ADF may instead be provided by the helmetcircuitry 300 (e.g., after interpreting data from the photodiode sensorand/or other sensor(s)). In this manner, when an arc 112 is present, thelens assembly 206 (and/or cover lens) may be darkened to protect theeyes of the operator 104, and when the arc 112 is not present the lensassembly 206 (and/or cover lens) may be lightened so that the operator104 can see the surrounding welding environment. In some examples, thephotodiode sensor (and/or other sensor(s)) may also be part of thewelding helmet 200, lens assembly 206, and/or ADF.

In some examples, the lens assembly 206 may further include one or moredisplay screens. In some examples, a display screen may be a near-eyedisplay. In some examples, the display screen(s) may be semi-transparentand/or configured to overlay information (e.g.,virtual/simulated/holographic objects, guidance, technique feedback,technique parameters, welding location feedback, welding location(s),welding sequence feedback, welding sequence(s), welding parameters,messages, etc.) onto at least part of cover lens (and/or lens assembly206). In some examples, the display screen may be integrated into safetyglasses attached to (and/or in communication with) the welding helmet200.

In some examples, a display screen may cover the entire cover lens(and/or lens assembly 206). In some examples where the display screencovers the entire cover lens (and/or lens assembly 206), the ADF may beomitted. In some examples, a display screen may cover only a portion ofthe cover lens (and/or lens assembly 206), so as to be visible on onlyone side (e.g., to only one eye). In some examples, providing thedisplay screen over both sides of the lens assembly 206 (and/or eyes)may make stereoscopic display possible, which may make it possible todisplay images that appear to have more depth. In some examples, adisplay screen may be positioned at and/or over a periphery of the lensassembly 206, so as to be less distracting.

In some examples the display screen(s) may be configured to displayinformation about certain aspects of the welding helmet 200. Forexample, the display screen(s) may display settings of the ADF, trackedwelding technique/operation/quality parameters, weldingtechnique/operation/quality parameters as compared to expectedparameters, welding technique/quality/operation feedback, workinstructions, welding procedure specification (WPS) information,parameters of the welding equipment 116, messages, manuals, trainingvideos/images, information about the workpiece 106, the joint about tobe welded, the location of the next weld, location of the joints alreadywelded, a virtual representation of the completed product being welded,walking directions to various locations, and/or other information. Insome examples, some of this information may be received from thecomputing system(s) 150 and/or a weld monitoring system. In someexamples, this information may be output via other helmet I/O devices208.

In the examples of FIGS. 2a-2b , the welding helmet 200 includes helmetinput/output (I/O) devices 208. In some examples, the helmet I/O devices208 are devices through which an operator 104 may provide input to,and/or receive output from, the welding helmet 200. In some examples,the I/O devices 208 may include knobs, buttons, levers, switches, touchscreens, microphones, speakers, haptic devices, lights (e.g., LEDs),and/or other appropriate I/O devices 208. In some examples, the displayscreen(s) may be considered part of the helmet I/O devices 208. In someexamples, settings of the ADF 220 may be controlled and/or presented tothe operator 102 via the helmet I/O devices 208. While shown as beingretained on an external surface of the helmet shell 202 in the examplesof FIGS. 2a-2b for the purposes of illustration, in some examples, someI/O devices 208 may also be retained on an internal surface of thehelmet shell 202.

In the examples of FIGS. 2a-2b , the welding helmet 200 also includesweld tracking sensors 102. While four weld tracking sensors 102 areshown, in some examples, the welding helmet 200 may include more orfewer weld tracking sensors 102. In some examples, the welding helmet200 may include at least two weld tracking sensors 102. In someexamples, the weld tracking sensors 102 of the welding helmet 200 may beattached to the helmet shell 202. In some examples, the weld trackingsensors 102 of the welding helmet 200 may be part of the lens assembly206 and/or ADF. In some examples, the weld tracking sensors 102 of thewelding helmet 200 may be positioned behind and/or covered by portionsof the lens assembly 206 (e.g., the cover lens) in order to protect theweld tracking sensors 102 from spatter, debris, and/or otherparticulates. In some examples, the weld tracking sensors 102 of thewelding helmet 200 may be positioned behind the ADF, so that light fromthe arc 112 will be filtered through the ADF and reduced beforeimpinging on the weld tracking sensors 102.

In some examples, the weld tracking sensors 102 of the welding helmet200 may be fixed relative to each other and/or the helmet shell 202. Insome examples, the relative positions of the weld tracking sensors 102of the welding helmet 200 may be known, stored, entered manually, and/orautomatically detected and/or derived during a calibration procedure. Aswith the weld tracking sensors 102 of FIG. 1, in some examples, the weldtracking sensors 102 of the welding helmet 200 shown in FIGS. 2a-2b maycomprise camera sensors, optical sensors, infra-red (IR) sensors,thermal sensors, acoustic sensors, ultrasonic sensors, and/or otherappropriate types of sensors. As with the weld tracking sensors 102 ofFIG. 1, in some examples, the weld tracking sensors 102 of the weldinghelmet 200 shown in FIGS. 2a-2b may be configured to track awelding-type operation by tracking the 6 DOF positions and/ororientations of the welding-type tool 110, arc 112, and/or workpiece(s)106.

In the example of FIG. 2b , the welding helmet 200 additionally includesa helmet tracking system 210. In some examples, the helmet trackingsystem 210 may be configured to track the 6 DOF position and/ororientation of the welding helmet 200 (and/or helmet tracking system210). In some examples, the helmet tracking system 210 may include itsown control circuitry to assist in the tracking, or the helmet circuitry300 may assist with the tracking. In some examples, it may be necessaryto keep track of the position and/or orientation of the welding helmet200 in order for the welding helmet 200 to operate as an independentweld tracking system. In the absence of the helmet tracking system 210,the welding helmet 200 might have difficulty distinguishing betweenmovement of the welding helmet 200 and movement of the welding-type tool110 and/or arc 112.

In some examples, the helmet tracking system 210 may be configured totrack a 6 DOF position and/or orientation of the welding helmet 200(and/or helmet tracking system 210) relative to some reference pointin/of the welding environment. In some examples, the reference point maybe some (e.g., stationary) object, point in space, point in a movingreference frame, and/or point in space occupied by the welding helmet200. In some examples, one or more stationary markers 114 may bepositioned at (and/or attached to) various locations around the weldingenvironment (e.g., on the ceiling, floor, wall(s), pillar(s), furniture,fixture(s), etc.) for the helmet tracking system 210 to use as referencepoints.

In some examples, the reference point may be chosen at initiation,startup, and/or reset of the helmet tracking system 210. In someexamples, the helmet tracking system 210 (and/or the welding helmet 200)may be configured to use a simultaneous localization and mapping (SLAM)algorithm to determine the 6 DOF position and/or orientation of thewelding helmet 200 relative to the reference point. In some examples,other algorithms (e.g., time of flight) may be used.

In some examples, the helmet tracking system 210 may provide relativelyreliable data during welding-type operations. However, movement of theoperator 104 tends to be much less dynamic during welding-typeoperations. In some examples, the helmet tracking system 210 may losetrack of the reference point and/or provide erroneous data if/when thereis rapid movement of the welding helmet 200. In situations where thereis too rapid and/or highly dynamic movement, the helmet tracking system210 may automatically reset.

In some examples, the helmet tracking system 210 may automatically resetwhen a new welding-type operation begins (e.g., after some thresholdperiod of inactivity) to ensure reliable data is gathered. In suchexamples, the welding helmet 200 may receive one or more signals fromthe welding-type tool 110 and/or welding-type equipment 116representative of an initiation of a welding-type operation by (e.g.,activation of) the welding-type tool 110. In some examples, the operator104 may manually reset the helmet tracking system 210 (e.g., via I/Odevice(s) 208). In some examples, the helmet tracking system 210 (and/orwelding helmet 200) may detect and/or determine the degree of movementof the welding helmet 200 and/or the corresponding reliability of thehelmet tracking system 210, and inform the operator 104 (e.g., via I/Odevice(s) 208) so that the operator can make a decision as to whether toreset the helmet tracking system 210.

In some examples, the helmet tracking system 210 may be fixed relativeto the helmet shell 202 and/or the weld tracking sensors 102 of thewelding helmet 200. In some examples, the helmet tracking system 210 maybe permanently affixed to the helmet shell 202 (e.g., via welding,molding, screws, etc.). In some examples, the helmet tracking system 210removably attached to the helmet shell 202 in such a way to allowrelatively easy removal and/or reattachment without the use of tools,such as, for example, through the use of adhesives, straps, hook andloop fasteners, magnets, clamps, and/or other appropriate mechanisms. Insome examples, allowing for easy removability of the helmet trackingsystem 210 may facilitate maintenance of the helmet tracking system 210.In some examples, the helmet shell 202 may include attachment features(e.g., adhesives, straps, hook and loop fasteners, magnets, etc.)configured to mate with complementary attachment features of the helmettracking system 210, to removably attach the helmet tracking system 210to the helmet shell 202. In some examples, the attachment features mayhelp to conduct electrical power from a power source 216 of the weldinghelmet 200 to the helmet tracking system 210.

In the example of FIG. 2b , the helmet tracking system 210 is affixedand/or attached to a rear portion of the helmet shell 202. In someexamples, this may help to increase the likelihood that the referencepoint used by the helmet tracking system 210 is a relatively stationarypoint in the environment. Were the helmet tracking system 210 insteadpositioned on the front portion of the helmet shell 202, there would bea nontrivial risk that a dynamic and/or moving point might be referenced(e.g., like the welding-type tool 110). In some examples, the helmettracking system 210 may instead be positioned on a side portion of thehelmet shell 202, which may also increase the likelihood that thereference point used by the helmet tracking system 210 is a stationarypoint in the welding environment. Additionally, rear and/or sideplacement of the helmet tracking system 210 may help to limitinterference due to the intense light, heat, and/or electromagneticradiation given off by the arc 112.

In the example of FIG. 2b , the helmet tracking system 210 comprises acombination of sensors, including one or more inertial measurement units(IMUs) 212 (e.g., comprising one or more accelerometers, gyroscopes,and/or magnetometers) and several camera sensors 214. As shown, thecamera sensors 214 are facing outward from the helmet shell 202. Whilethree camera sensors 214 are shown in the example of FIG. 2b , in someexamples, more or fewer camera sensors 214 may be used. In someexamples, additional or alternative sensors may be used, such as, forexample, acoustic sensors, ultrasonic sensors, IR sensors, infraredprojectors/detectors, near field communication (NFC) sensors, radiofrequency identification (RFID) sensors, thermal sensors, and/or otherappropriate sensors. In some examples, the IMU 212, camera sensors 214,and/or other sensors may be positioned behind a casing, housing, and/orother covering to protect against spatter, debris, and/or otherparticulates.

In some examples, the IMU 212, camera sensors 214, and/or other sensorsof the helmet tracking system 210 may capture (e.g., image and/orinertial) data relating to the position and/or orientation of thewelding helmet 200 (and/or helmet tracking system 210). In someexamples, this data may be analyzed to determine the position and/ororientation of the welding helmet 200 (and/or helmet tracking system210) relative to a reference point. In some examples, the helmettracking system 210 (and/or the welding helmet 200) may be configured touse a simultaneous localization and mapping (SLAM) algorithm todetermine the 6 DOF position and/or orientation of the welding helmet200 relative to the reference point. In some examples, the helmettracking system 210 may include its own control circuitry to assist inthe determinations. In some examples, the helmet circuitry 300 mayassist with the determinations.

In some examples, the welding helmet 200 may be calibrated in order toassist with tracking the 6 DOF position and/or location of the weldinghelmet 200, welding-type tool 110, arc 112, and/or workpiece(s) 106. Forexample, the welding helmet 200 may be calibrated so that a direction ofgravity is known. As another example, the welding helmet 200 may becalibrated to derive and/or determine a positional, rotational, and/orframe of reference relationship between the weld tracking sensors 102and helmet tracking system 210 of the welding helmet 200. In someexamples, the calibration may be performed automatically. In someexamples, there may be a calibration procedure that may be performed atinitiation and/or reset. In some examples, the welding helmet 200 may beplaced in a known orientation (e.g., on a flat surface) beforecalibrating.

In some examples, calibration may assist the welding helmet 200 inaccurately determining certain technique parameters (e.g., work angle).For example, knowing the direction of gravity may allow the weldinghelmet 200 to determine a plane of the welding bench 108 (e.g.,perpendicular to the direction of gravity, assuming a flat bench 108),which may help to fully define an orientation of a workpiece 106(assuming it is placed on the welding bench 108 or similar surface). Insome examples, many of the technique parameters may still be accuratelydetermined, even without the calibration.

In the examples of FIGS. 2a-2b , the welding helmet 200 further includeshelmet circuitry 300 and a helmet power source 216. In some examples,the helmet circuitry 300 and helmet power source 216 may be internal tothe helmet shell 202. In some examples, the helmet power source 216 mayprovide electrical power to the components of the welding helmet 200. Insome examples, the power source 216 may comprise one or more batteries,solar panels, and/or energy harvesting devices. In some examples, one ormore components of the welding helmet 200 (e.g., the helmet trackingsystem 210, ADF, etc.) may have a separate power source from which todraw power. In some examples, the helmet circuitry 300 may support,drive, and/or facilitate operation of the welding helmet 200.

FIG. 3 is a block diagram showing components and interconnections of theweld tracking system 100. In particular, FIG. 3 shows more detailedcomponents of the computing system 150 and helmet circuitry 300. Whilenot shown, the computing system 150 may further include a power sourceconfigured to provide electrical power to the computing system 150.

In the example of FIG. 3, the helmet circuitry 300 includes helmetmemory circuitry 302, helmet processing circuitry 304, helmetcommunication circuitry 306, and helmet I/O circuitry 308 interconnectedwith one another via a common electrical bus. The helmet circuitry 300is also in electrical communication with the I/O devices 208, the lensassembly 206, the weld tracking sensors 102 of the welding helmet 200,and the helmet tracking system 210.

In the example of FIG. 3, the computing system 150 includes computingmemory circuitry 152, computing processing circuitry 154, computingcommunication circuitry 156, and computing UI circuitry 158interconnected with one another via a common electrical bus. Thecomputing system is also in electrical communication with the UI 151 ofthe computing system 150. In the example of FIG. 3, both the computingsystem 150 and the welding helmet 200 are in communication with thewelding-type tool 110, the welding equipment 116, the fixed weldtracking sensors 102 positioned around the welding environment, and eachother.

In some examples, the UI circuitry 158 and/or I/O circuitry 308 maycomprise one or more drivers for the UI 151 and/or I/O devices 208,respectively. In some examples, the UI circuitry 158 and/or I/Ocircuitry 308 may be configured to generate one or more signalsrepresentative of input received via the UI 151 and/or I/O devices 208,respectively, and provide the signal(s) to the bus. In some examples,the UI circuitry 158 and/or I/O circuitry 308 may also be configured tocontrol the UI 151 and/or I/O devices 208, respectively, to generate oneor more outputs in response to one or more signals (e.g., received viathe bus).

In some examples, the helmet communication circuitry 306 and/orcomputing communication circuitry 156 may include one or more wirelessadapters, wireless cards, cable adapters, wire adapters, dongles, radiofrequency (RF) devices, wireless communication devices, Bluetoothdevices, IEEE 802.11-compliant devices, WiFi devices, cellular devices,GPS devices, Ethernet ports, network ports, lightning cable ports, cableports, etc. In some examples, the helmet communication circuitry 306and/or computing communication circuitry 156 may be configured tofacilitate communication via one or more wired media and/or protocols(e.g., Ethernet cable(s), universal serial bus cable(s), etc.) and/orwireless mediums and/or protocols (e.g., cellular communication, generalpacket radio service (GPRS), near field communication (NFC), ultra highfrequency radio waves (commonly known as Bluetooth), IEEE 802.11x,Zigbee, HART, LTE, Z-Wave, WirelessHD, WiGig, etc.). In some examples,the helmet communication circuitry 306 and/or computing communicationcircuitry 156 may be coupled to one or more antennas to facilitatewireless communication.

In some examples, the helmet communication circuitry 306 and/orcomputing communication circuitry 156 may be configured to facilitatecommunications of the computing system 150 and the welding helmet 200.In some examples, the helmet communication circuitry 306 and/orcomputing communication circuitry 156 may receive one or more signals(e.g., from the fixed weld tracking sensors 102, welding-type tool 110,welding-type equipment 116, etc.) decode the signal(s), and provide thedecoded data to the electrical bus. As another example, the helmetcommunication circuitry 306 and/or computing communication circuitry 156may receive one or more signals from the electrical bus (e.g.,representative of one or more inputs received via the UI circuitry 158and/or I/O circuitry 308) encode the signal(s), and transmit the encodedsignal(s) to an external device (e.g., the weld tracking sensors 102,welding-type tool 110, welding-type equipment 116, etc.).

In some examples, the computing processing circuitry 154 and/or helmetprocessing circuitry 304 may comprise one or more processors,controllers, and/or graphical processing units (GPUs). In some examples,the helmet processing circuitry 304 may comprise one or more drivers forthe weld tracking sensors 102 and/or helmet tracking system 210 of thewelding helmet 200. In some examples, the computing processing circuitry154 and/or helmet processing circuitry 304 may comprise countercircuitry and/or clock circuitry. In some examples, the computingprocessing circuitry 154 and/or helmet processing circuitry 304 may beconfigured to execute machine readable instructions stored in thecomputing memory circuitry 152 and/or helmet memory circuitry 302.

In the example of FIG. 3, the computing memory circuitry 152 and helmetmemory circuitry 302 includes (and/or stores) a weld tracking process400. The weld tracking process 400 is shown as being part of (and/orstored in) both the computing memory circuitry 152 and helmet memorycircuitry 302 to show that, in some examples, either or both thecomputing system 150 and welding helmet 200 may perform the weldtracking process 400. In the discussion below, the general term memoryis sometimes used to refer to computing memory circuitry 152 and/orhelmet memory circuitry 302.

In some examples, the weld tracking process 400 may comprise machinereadable instructions stored in memory and/or configured for executionby the computing processing circuitry 154 and/or helmet processingcircuitry 304. In some examples, the weld tracking process 400 may beimplemented via discrete circuitry (e.g., of the computing processingcircuitry 154 and/or helmet processing circuitry 304) rather than, or inaddition to, being part of (and/or stored in) the computing memorycircuitry 152 and/or helmet memory circuitry 302.

While not shown in the example of FIG. 3, in some examples, thecomputing memory circuitry 152 and/or helmet memory circuitry 302 mayalso include (and/or store) machine readable instructions comprisingcounter and/or clock programs. In some examples, the computing memorycircuitry 152 and/or helmet memory circuitry 302 may also include(and/or store) one or more determined, target, present, and/or pastparameters (e.g., welding, welding technique, weld quality, and/orwelding operation parameters). In some examples, one or more parametersmay be associated with timestamp, job, project, WPS, work order,equipment, and/or other information. In some examples, the weld trackingprocess 400 may use and/or update one or more of the stored parametersduring operation.

In some examples, the weld tracking process 400 may process datacaptured by weld tracking sensors 102 and track, from the captured data,the 6 DOF position and/or orientation of the welding-type tool 110, arc112, and/or workpiece(s) 106. The weld tracking process 400 may furtheranalyze the 6 DOF position and/or orientation of the welding-type tool110, arc 112, and/or workpiece(s) 106, and determine certain weldingtechnique, weld quality, and/or welding operation parameters based onthe position and/or orientation data. In some examples, the weldtracking process 400 may provide feedback to an operator 104 regardingthe determined welding technique, weld quality, and/or welding operationparameters, in view of one or more target and/or expected weldingtechnique, weld quality, and/or welding operation parameters.

FIG. 4 is a flowchart illustrating operation of an example weld trackingprocess 400. In the example of FIG. 4, the weld tracking process 400begins at block 402. At block 402, the weld tracking process 400initializes components of the weld tracking system 100 and/or thewelding helmet 200. In some examples, this may include initializing theweld tracking sensors 102 fixed in the welding environment and/orsecured to the welding helmet 200. In some examples, at block 402, theweld tracking process 400 may initialize the helmet tracking system 210to select a reference point.

In some examples, at block 402, the weld tracking process 400 mayreceive one or more inputs from the operator 104. In some examples, theinput(s) may be used to configure the weld tracking system 100 and/orweld tracking process 400. For example, the operator 104 may enterwelding parameters into the welding-type equipment (e.g., via theoperator interface 130). In some examples, the welding parameter(s) maybe communicated to the welding helmet 200 and/or computing system 150 atblock 402.

As another example, the operator 104 may enter information (e.g., via UI151, I/O device(s) 208, etc.) relating to an upcoming welding-typeoperation. Information relating to the upcoming welding-type operationmay include, for example, the related job, project, WPS, work order,welding location(s), welding path(s), sequenced order of welds, expectedwelding parameters for each weld, expected welding technique parametersfor each weld, expected weld quality for each weld, and/or otherpertinent information. In some examples, this information mayalternatively, or additionally, be automatically loaded from memorybased on some selection (e.g., of a job, project, WPS, work order,etc.), detection (e.g., a barcode, NFC device, etc.), and/or other data.In some examples, the information may be communicated to the weldinghelmet 200 and/or computing system 150 at block 402.

In some examples, the weld tracking process 400 may perform and/orundergo certain calibrations at block 402. For example, the weldtracking process 400 may be calibrated to recognize the markers 114 onthe welding-type tool 110, and/or correctly correlate them with astructural configuration and/or model in memory. As another example, theweld tracking process 400 may calibrate the direction of gravity for thewelding helmet 200 (and/or helmet tracking system 210). As anotherexample, the weld tracking process 400 may be calibrated with therelative locations of the weld tracking sensors 102 within the weldingenvironment and/or on the welding helmet 200. As another example, theweld tracking process 400 may be calibrated with the relative locationsof the weld tracking sensors 102 on the welding helmet 200 with respectto the helmet tracking system 210.

As another example, the weld tracking process 400 may be calibrated withthe relative locations of the weld tracking sensors 102 on the weldinghelmet 200 with respect to the display screen(s). For example, the weldtracking process 400 may prompt the operator 104 to “touch” (e.g., withthe calibration tool 132) points displayed at corners (and/or otherportions) of the display screen(s). By understanding the spatialrelationship(s) between the display screen(s) (e.g., showing thepoint(s) that are “touched”) and the weld tracking sensors 102 (e.g.,capturing data relating to the position/orientation of the calibrationtool 132 “touching” the point(s)) the weld tracking process 400 canbetter display virtual feedback and/or other information relative(and/or anchored) to items in the real world.

As another example, the weld tracking process 400 may be calibrated torecognize one or more joints of a workpiece 106. This would allow theweld tracking process 400 to know the location and/or path geometry ofthe joint before welding begins, which may have several benefits. Forexample, the joint to be worked may be highlighted (e.g., via the UI 151and/or I/O devices 208) before the welding-type operation begins.Additionally, knowledge of the joint and/or path geometry may aid indetermining welding technique parameters. For example, the aim weldingtechnique parameter may be more accurately measured with thisinformation. Further, accurate aim technique during welding-typeoperations may ensure that a weld is placed in the center of the jointrather than offset to one side or the other.

In some examples, the calibration tool 132 and/or welding-type tool 110may be used to calibrate the weld tracking process 400 to recognize thegeometry of a joint of the workpiece 106. For example, the operator 104may use the calibration tool 132 and/or welding-type tool 110 toidentify endpoints (and/or intermediate points) of a joint (and/or weldpath) by pointing the calibration tool 132 and/or welding-type tool 110at the point and then activating. In some examples, there may be aparticular way of activating the calibration tool 132 and/orwelding-type tool 110 to indicate identification of an endpoint and/orintermediate point. For example, two or three quick, less than one ortwo second, activations in quick succession.

In some examples, the weld tracking process 400 may be put into acalibration mode (e.g., via input(s) 134, UI 151, operator interface130, I/O device(s) 208, etc.) before some or all of the calibrations.This may ensure activation of the calibration tool 132 and/orwelding-type tool 110 is correctly interpreted. However, in someexamples, the calibration may be done in an operational mode.

In examples where calibration may be done in an operational mode, theidentification of the endpoint (and/or intermediate point) may bethrough a short, less than one or two second, welding-type operation(e.g., a tack weld). This may be convenient, as some welding-typeoperations call for tack welds along and/or on opposite ends of a jointand/or weld path prior to the primary welding-type operation anyway.Further, the calibration prior to the primary welding-type operation mayallow the weld tracking process 400 to highlight the joint and/or weldpath to the operator 104 (e.g., via the UI 151 and/or I/O device(s)208), which may assist the operator 104 during the welding-typeoperation.

In some examples, the operator 104 may calibrate the weld trackingprocess 400 during performance of the welding-type operation. Forexample, the operator 104 may identify one endpoint (e.g., using theabove discussed process), and then start the welding-type operation atthe opposite endpoint. In such an example, the weld tracking process 400may conclude that the welding-type process started at the oppositeendpoint, and determine the joint and/or weld path as being a lineand/or the shortest path between the two endpoints (where shortest pathmay be a curve instead of a straight line for pipe welds and/or othercurved welds).

FIGS. 5a-5d illustrate the joint and/or weld path recognitioncalibration of the weld tracking process 400 using the calibration tool132 and/or welding-type tool 110. FIG. 5a shows an example of thecalibration tool 132 being used to identify a first endpoint 502 a ofthe joint and/or weld path. In some examples, the weld tracking process400 may capture data relating to the calibration tool 132 (e.g., via theweld tracking sensors 102), identify the position/orientation of thecalibration tool 132 using the captured data, and identify the positionof endpoint 502 a from this data (and/or known/detectedposition/orientation data relating to the workpiece 106) when thecalibration tool 132 is activated (e.g., via input(s) 134). FIG. 5bshows an example of how the endpoint 502 a might be depicted to theoperator 104 on a display screen 504 (e.g., of the UI 151, lens assembly206, and/or I/O device(s) 208) after the calibration tool 132 isactivated to perform the calibration. While the calibration tool 132 isshown being used in FIG. 5a , in some examples, the welding-type tool110 may be used instead.

FIG. 5c shows an example of the welding-type tool 110 being used toidentify a second endpoint 502 of the joint and/or weld path. As shown,the welding-type tool 110 is performing a welding-type operation (e.g.,starting tack or primary welding-type operation), which generates an arc112 and a molten pool. In some examples, the weld tracking process 400may capture data relating to the welding-type tool 110 and/or arc 112(e.g., via the weld tracking sensors 102), identify theposition/orientation of the welding-type tool 110 and/or arc 112 basedon the captured data, and identify the position of the second endpoint502 b from this data (and/or known/detected position/orientation datarelating to the workpiece 106) when the welding-type operation isinitiated via the welding-type tool 110 (e.g., via activation of thetrigger 111). While the welding-type tool 110 is shown being used inFIG. 5c , in some examples, the calibration tool 132 may be usedinstead.

FIG. 5d shows an example of how the endpoints 502 and the highlight 506connecting the endpoints 502 might be depicted to the operator 104 onthe display screen 504 after both endpoints 502 are identified. In someexamples, an estimated distance between endpoints 502 (e.g., asdetermined by the weld tracking process 400 using data captured by theweld tracking sensors 102) may also be depicted on the display screenand/or otherwise output (e.g., via I/O device(s) 208, UI 151, etc.). Forexample, the depiction of the distance between endpoints 502 may beshown on or adjacent the highlight 506 and/or endpoint(s) 502, or at aperimeter of the display screen.

In some examples, feedback as to whether the distance is within athreshold range of an expected distance (e.g., provided by themonitoring system) may also be provided, as well as how to correct ifnecessary. In some examples, feedback as to whether the position(s) ofthe endpoints(s) 502 (and/or connected path) are within a thresholddistance of an expected position (e.g., provided by the monitoringsystem) may also be provided, as well as how to correct if necessary.

In some examples, the highlight 506 may be shown prior to identificationof the second endpoint 502 b. For example, the welding-type tool 110 (orcalibration tool 132) may be used to identify the first endpoint 502 a(as discussed above). Thereafter, the highlight 506 may be shownextending from the first endpoint 502 a to the (e.g., nozzle) tip of thewelding-type tool 110 (or calibration tool 132). Thus, as thewelding-type tool 110 (or calibration tool 132) is moved away from thefirst endpoint 502 a, the highlight 506 may be depicted as lengtheningto extend between the first endpoint 502 a and the moving welding-typetool 110 (or calibration tool 132).

In some examples, the second endpoint 502 b may also be depicted asmoving with the welding-type tool 110 (or calibration tool 132). Forexample, the second endpoint 502 b may be shown continually positionedat (and/or anchored to) the (e.g., nozzle) tip of the welding-type tool110 (or calibration tool 132), until the final position of the secondendpoint 502 b is identified. In such examples, the highlight 506 wouldalways be depicted as extending between the endpoints 502. In someexamples, an estimated distance between endpoints 502 (and/or feedbackregarding the distance/position(s)) may be shown and/or continuallyupdated as the welding-type tool 110 (or calibration tool 132) moves.

While depictions of the calibration tool 132 and welding-type tool 110are omitted in the examples of FIGS. 5b and 5d for the sake of space andsimplicity, in some examples, the calibration tool 132 and/orwelding-type tool 110 may also be shown in the display screen 504. Insome examples, the endpoints 502, highlight 506, and/or other feedbackmay be graphics overlayed on a transparent cover lens such that theoperator 104 sees the endpoints 502, highlight 506, and/or otherfeedback superimposed on the real life workpiece 106 through the coverlens.

In some examples, the weld tracking process 400 may be calibrated torecognize the complete geometry of the workpiece(s) 106. This may allowthe weld tracking process 400 to automatically identify the joints ofthe workpiece(s) 106 and/or intended weld paths, such as, for example,based on one or more work instructions, WPS, and/or models of theworkpiece 106 stored in memory. In some examples, the calibration tool132 and/or welding-type tool 110 may be used to identify (and/or theoperator 104 may manually input) the geometry of the workpiece(s) 106.For example, the calibration tool 132 and/or welding-type tool 110 maybe used to identify (and/or the operator 104 may manually input)particular points on the perimeter(s) of workpiece(s) 106, distancedfrom one another as much as possible. In some examples, these points maybe used by the weld tracking process 400 to automatically determine ageometry of the workpiece(s) 106. In some examples, at least threepoints may be identified. In some examples, the points may be indifferent planes.

In the example of FIG. 4, the weld tracking process 400 proceeds toblock 404 after block 402. At block 404, the weld tracking process 400tracks a 6 DOF position and/or orientation of the welding helmet 200relative to a reference point, via the helmet tracking system 210. Insome examples, this may involve capturing data via the camera sensors214 and/or IMU(s) 212 of the helmet tracking system 210, and/oranalyzing the captured data determine what changes have occurred sinceinitialization and/or reset.

In some examples, the SLAM algorithm may be used to determine thechanges in position and/or orientation based on the captured data. Insome examples, the SLAM algorithm may implement a continuous learningand/or training operation, whereby differences in data captured by thecamera sensors 214 may be analyzed in conjunction with data captured bythe IMU 212 to determine accurate movement information relative to thereference point, without the need for prior knowledge of the weldingenvironment.

In some examples, the helmet tracking system 210 may perform all or someof the data interpretation and/or analytics, and the weld trackingprocess 400 may simply use the results. In some examples, the weldtracking process 400 may be involved in the data interpretation and/oranalytics to determine the resulting position and/or orientation of thewelding helmet 200. In some examples, the fixed weld tracking sensors102 may also be used to help track the welding helmet 200 (e.g., viamarkers 114 attached to the welding helmet 200), though this may negateone of the benefits of using the welding helmet 200 as an independentmobile tracking system.

In the example of FIG. 4, the weld tracking process 400 proceeds toblock 406 after block 404. At block 406, the weld tracking process 400tracks the 6 DOF position and/or orientation of the welding-type tool110 and/or arc 112 relative to the weld tracking sensors 102, using datacaptured by the weld tracking sensors 102, as discussed above. In someexamples, the weld tracking process 400 may analyze the data captured bythe weld tracking sensors 102 to identify the positions and/ororientations of the welding-type tool 110 and/or arc 112. In someexamples, the markers 114 on the welding-type tool 110 may assist inidentification, recognition, and/or tracking of the welding-type tool110 via the captured data. In some examples, data measured by sensors ofthe welding-type tool 110 and/or communicated to the computing system150 and/or welding helmet 200 may also assist tracking the welding-typetool 110. In some examples, the 6 DOF position/orientation of theworkpiece(s) 106 may also be tracked at block 404.

In the example of FIG. 4, the weld tracking process 400 proceeds toblock 408 after block 406. At block 408, the weld tracking process 400determines the three dimensional position and/or orientation of thewelding-type tool 110 and/or arc 112 in the welding environment (and/orworld space). In some examples, the three dimensional position and/ororientation of the workpiece(s) 106 may also be determined. In someexamples, these determinations may be based on the prior determinationsmade at blocks 404 and 406. In examples where only the environment fixedweld tracking sensors 102 are used, these determinations may berelatively simple.

However, in examples where the weld tracking sensors 102 of the weldinghelmet 200 are used, the weld tracking process 400 may have to factor inmovement and/or changes in position/orientation of the welding helmet200 when determining the position and/or orientation of the welding-typetool 110 and/or arc 112. In such examples, the determination at block408 may involve one or more reference frame transformations to determinethe position and/or orientation of the welding-type tool 110 and/or arc112. Such reference frame transformations may use both the positionand/or orientation of the welding helmet 200 relative to the referencepoint, and the positions and/or orientations of the welding-type tool110 and/or arc 112 relative to the welding helmet 200 (and/or its weldtracking sensors 102). The reference frame transformations may result ina determination of a three dimensional position and/or orientation ofthe welding-type tool 110 and/or arc 112 relative to the reference point(and/or in world space).

FIG. 7 is a diagram depicting example position, orientation, and/orreference frame relationships between the welding helmet 200, referencepoint 702, welding-type tool 110, and/or arc 112. In some examples, therelationships are depicted and/or interpreted using vectors, matrices,vector mathematics, and/or matrix mathematics. In some examples, thedepicted relationships may be useful in understanding how the weldtracking process 400 determines a three dimensional position and/ororientation of the welding-type tool 110 and/or arc 112 relative to areference point (and/or in world space).

In the example of FIG. 7, a reference point 702 is shown remote fromboth the welding helmet 200 and welding-type tool 110. In some examples,the reference point 702 may have been selected as part of block 402 ofthe weld tracking process 400. In some examples, a world space frame ofreference is imposed using the reference point 702, with the referencepoint 702 acting as an origin of a coordinate system centered about thereference point 702.

In the example of FIG. 7, a position vector 704RH is shown connectingthe reference point 702 to the helmet tracking system 210 of the helmet200. In some examples, the position vector 704RH represents a positionof the helmet 200 and/or helmet tracking system 210 relative to thereference point 702.

In the example of FIG. 7, position vectors 704HWa and 704HWb aredepicted connecting the helmet tracking system 210 to two weld trackingsensors 102 of the helmet 200. In some examples, the position vectors704HW represent the position(s) of the weld tracking sensor(s) 102relative to the helmet tracking system 210. As shown, a position vector704WT connects a first weld tracking sensor 102 a to the welding-typetool 110, and a position vector 704WA connects a second weld trackingsensor 102 b to the arc 112 produced by the welding-type tool 110. Insome examples, the position vector 704WT and position vector 704WArepresent a position of the welding-type tool 110 and arc 112,respectively, relative to the weld tracking sensor(s) 102.

In the example of FIG. 7, an orientation vector 706 is also depicted foreach of the helmet tracking system 210, weld tracking sensors 102,welding-type tool 110, and arc 112. In some examples, each orientationvector 706 is representative of an orientation (and/or rotation/angle)of an object (and/or the object's reference frame) relative to anotherobject (and/or that object's reference frame). For example, theorientation vector 706O_(RH) is representative of the orientation of thehelmet tracking system 210 (and/or the reference frame of the helmettracking system 210) relative to the reference point 702 (and/or thereference frame of the reference point 702). As another example, theorientation vector 706O_(HW) is representative of the orientation of theweld tracking sensors 102 relative to the helmet tracking system 210. Asanother example, the orientation vector 706O_(WT) is representative ofthe orientation of the welding-type tool 110 relative to the weldtracking sensors 102. As another example, the orientation vector706O_(WA) is representative of the orientation of the arc 112 relativeto the weld tracking sensors 102.

While only one orientation vector 706O_(HW) is depicted for multipleweld tracking sensors 102, in some examples, each weld tracking sensor102 may be associated with its own orientation vector 706. Likewise, insome examples, there may be separate orientation vectors 706O_(WA)and/or orientation vectors 706O_(WT) for each weld tracking sensor 102.In some examples, all the weld tracking sensors 102 may share the sameorientation vectors 706.

While only two weld tracking sensors 102 and two position vectors 704HWare shown in the example of FIG. 7, in some examples, more may be usedand/or applicable. Though one position vector 704WT and one positionvector 704WA are each shown extending from one weld tracking sensor 102for the sake of simplicity and clarity, in some examples a positionvector 704WT and/or position vector 704WA may be considered to extendfrom each weld tracking sensor 102.

While the position vector 704RH and position vector 704HW are shownconnecting to separate portions of the helmet tracking system 210 forthe sake of clarity, in some examples, the position vectors 704 may beconstructed to extend from the same point(s) (e.g., a midpoint). Thoughone position vector 704RH is shown for the entire helmet tracking system210 in the example of FIG. 7, in some examples, a separate positionvector 704RH may be considered to exist for each particular sensor ofthe helmet tracking system 210. Likewise, in some examples, separateposition vectors 704HW may be considered to exist for each particularsensor of the helmet tracking system 210.

While the position vector 704WT and position vector 704RT are each shownextending to an approximate midpoint of a handle of the welding-typetool 110, in some examples the endpoint for the position vectors 704 maybe considered to be at some other point of the welding-type tool 110(e.g., at a midpoint/endpoint of the neck, nozzle, or electrode).Likewise, though the position vector 704WA is depicted extending to anapproximate midpoint of the arc 112, in some examples, the positionvector 704 may instead terminate at some other point along the arc 112.

In the example of FIG. 7, an orientation equation 708 is depicted. Insome examples, the orientation equation 708 represents a relationshipbetween the various orientation vectors 706 shown in FIG. 7. Inparticular, the orientation equation 708 indicates that the orientationvector 706O_(TR) (representative of the orientation of the welding-typetool 110 relative to the reference point 702) is equal to theorientation vector 706O_(RH) multiplied by the orientation vector706O_(HW) and the orientation vector 706O_(WT). In other words, theorientation of the welding-type tool 110 relative to the reference point702 (706O_(TR)) is equal to the combined orientations of the helmettracking system 210 (relative to the reference point 702), weld trackingsensor(s) 102 (relative to the helmet tracking system 210), andwelding-type tool 110 (relative to the weld tracking sensor(s) 102).

In some examples, the orientation equation 708 may be modified to applyto the orientation of the arc 112 rather than the orientation of thewelding-type tool 110. In particular, the orientation equation 708 maybe made to apply to the arc 112 by replacing the orientation vector 706O_(TR) with the orientation vector 706O_(AR) (representative of theorientation of the arc 112 relative to the reference point 702), andreplacing the orientation vector 706O_(WT) (representative of theorientation of the welding-type tool 110 relative to the weld trackingsensor(s) 102) with the orientation vector 706 O_(WA) (representative ofthe orientation of the arc 112 relative to the weld tracking sensor(s)102).

In the example of FIG. 7, a position equation 710 is also depicted. Insome examples, the position equation 710 represents a relationshipbetween the various position vectors 704 and orientation vectors 706shown in FIG. 7.

In particular, the position equation 710 indicates that the positionvector 704RT (representative of the position of the welding-type tool110 relative to the reference point 702) is equal to position vector704RH (representative of the position of the helmet tracking system 210relative to the reference point 702) plus two parenthetical vectors. Thefirst parenthetical vector is equal to the position vector 704HWmultiplied by the orientation vector 706O_(RH). The second parentheticalvector is equal to the position vector 704WT multiplied by theorientation vector 706O_(RH) and the orientation vector 706O_(HW). Inother words, the position of the welding-type tool 110 relative to thereference point 702 is equal to the position of the welding-type tool110 relative to the weld tracking sensor(s) 102, plus the position ofthe weld tracking sensor(s) 102 relative to the helmet tracking system210, plus the position of the helmet tracking system 210 relative to thereference point 702 (taking into account the relative orientations ofthe helmet tracking system 210 and weld tracking sensor(s) 102).

In some examples, the position equation 710 may be modified to apply tothe position of the arc 112 rather than the position of the welding-typetool 110. In particular, the position equation 710 may be modified toapply to the position of the arc 112 by replacing the position vector704RT with the position vector 704RA (not shown, but representative ofthe position of the arc 112 relative to the reference point 702), andreplacing the position vector 704WT with the position vector 704WA.

In some examples where there are considered to be different positionvectors 704 and/or orientation vectors 706 for different weld trackingsensors 102 (and/or different sensors of the helmet tracking system210), the orientation equation 708 and/or position equation 710 maystill hold true as long as the orientation vectors 706 are consistent(e.g., where orientation vector 706O_(HW) and orientation vector706O_(WT) are relative to the same weld tracking sensor(s) 102), and/orthe path of the position vectors 704 are interconnecting and/orcontinuous (e.g., where position vector 704HW and position vector 704WTboth connect to the same weld tracking sensor 102). In some suchexamples, different implementations of the orientation equation 708and/or position equation 710 (using different weld tracking sensors 102and/or different sensors of the helmet tracking system 210) may yieldslightly different results. In some such examples, the different resultsmay be averaged together (and/or otherwise statistically analyzed and/ormanipulated) to get a single (and/or more accurate) result.

In some examples, the weld tracking process 400 may use the positionequation 710 and/or orientation equation 708 to determine a threedimensional position and/or orientation of the welding-type tool 110and/or arc 112 relative to the reference point 702. In some examples,the weld tracking process 400 may use one or more matrices to representand/or implement one or more orientation vectors 702 and/or positionvectors 704. In some examples, the weld tracking process 400 may use oneor more quaternions and/or Euler angles to represent and/or implementone or more of the orientation vectors 702 and/or position vectors 704.In some examples, the weld tracking process 400 may apply appropriatematrix mathematics to the orientation equation 708 and/or positionequation 710 at block 408.

In the example of FIG. 4, the weld tracking process 400 proceeds toblock 410 after block 408. At block 410, the weld tracking process 400determines one or more welding technique and/or welding operationparameters based on the position(s) and/or orientation(s) of thewelding-type tool 110 and/or arc 112 determined at block 408. In someexamples, the weld tracking process 400 may also useposition/orientation information about the workpiece(s) 106 and/orcalibration information provided at block 402 to determine the weldingtechnique and/or welding operation parameter(s).

In some examples, the welding technique parameters may includeposition/orientation, travel speed, travel direction, travel angle, workangle, contact to work distance, and/or aim of the welding-type tool110. In some examples, the welding technique parameters may include oneor more weld bead/path characteristics, such as, for example, a length,straightness, weave, whip, and/or position of the weld bead/path, and/ora distance between weld beads/paths. In some examples, data relating tothe movement of the welding-type tool 110 and/or arc 112 along theentire weld path and/or joint may be evaluated to determine the weldbead/path characteristics. In some examples, other information may alsobe determined, such as, for example, a duration of the welding-typeoperation and/or a number of performed welding-type operations.

In some examples, the welding technique parameters determined by theweld tracking process 400 may depend upon certain aspects of the weldtracking process 400 and/or the weld tracking system 100. For example,the weld tracking process 400 may be able to determine more weldingtechnique parameters when tracking just the welding-type tool 110 thanwhen tracking just the arc 112. For instance, while it may still bepossible to determine travel speed when tracking just the arc 112, itmay be more difficult to track other welding technique parameters (e.g.,work angle, travel angle, contact to work distance, etc.). On the otherhand, it may be simpler and/or easier to track just the arc 112, whiletracking the welding-type tool 110 may be a more complicated matter.

As another example, the weld tracking process 400 may be able todetermine more welding technique parameters when calibrated to recognizethe geometry of the workpiece(s) 106 and/or joint(s)/weld path(s) thanwhen otherwise. In some examples, the calibration may allow the weldtracking process 400 to determine the spatial relationship(s) betweenthe workpiece(s) 106 (and/or its joint(s)/weld path(s)) and thewelding-type tool 110 and/or arc 112. In some examples, the spatialrelationship(s) can be important for determining some welding techniqueparameters (e.g., work angle, aim, etc.). On the other hand, it may besimpler and/or easier for an operator 104 if no calibration is required.

In some examples, the contact tip to work distance welding techniqueparameter may be determined without calibration when tracking both thewelding-type tool 110 and arc 112. For example, the weld trackingprocess 400 may identify the position and/or orientation of severalpoints in space that comprise the (e.g., detectable/visible portions of)arc 112, then identify the point of the (e.g., detectable/visible) arc112 that is farthest from the welding-type tool 110 (and/or a nozzle ofthe welding-type tool 110). Thereafter, the weld tracking process 400may estimate the distance between the far point of the (e.g.,detectable/visible) arc 112 and the welding-type tool 110 (and/or anozzle of the welding-type tool 110) as being the contact tip to workdistance.

As another example, the weld tracking process 400 may identify theposition and/or orientation of several points in space that comprise the(e.g., detectable/visible) arc 112, then identify the points of the(e.g., detectable/visible) arc 112 that are closest to and farthest fromthe welding-type tool 110 (and/or a nozzle of the welding-type tool110). Thereafter, the weld tracking process 400 may estimate thedistance between the two points as being the contact tip to workdistance and/or (e.g., detectable/visible) arc length. Though, in someexamples, this may be a coarse and/or approximate estimate, it may stillbe useful. In some examples, the weld tracking system 100 may alsodetermine contact to work distance when tracking just the welding-typetool 110, if the weld tracking system 100 has been calibrated with thegeometry of the workpiece 106 and/or joint(s), by determining thedistance between the welding-type tool 110 (and/or the nozzle of thewelding-type tool 110) and the workpiece 106 and/or joint.

In some examples, the welding operation parameters may include weldinglocation information and/or weld sequence information. In some examples,welding location information may include one or more (e.g., coordinate)locations of a weld produced by the arc 112 and/or the currentwelding-type operation. In some examples, weld sequence information mayinclude information relating to an ordered sequence of welds produced bythe operator 104 and/or welding-type tool 110 for a particular job, workorder, WPS, and/or project, and/or within a threshold range of time. Insome examples, the ordered sequence of welds may include the currentweld produced by the arc 112 and/or the current welding-type operation.In some examples, the weld sequence information may include, forexample, the relative welding locations of the current weld and/or oneor more previously produced welds.

In some examples, the weld tracking process 400 may identify a positionof (e.g., a nozzle of) the welding-type tool 110 and positions of thearc 112 closest and farthest from the (e.g., nozzle of the) welding-typetool 110, and estimate the welding location(s) to be at the point of thearc 112 farthest from the (e.g., nozzle of the) welding-type tool 110.In some examples, the weld tracking process 400 may identify where thearc 112 intersects the workpiece 106, and estimate the weldinglocation(s) to be at the point(s) of intersection. As another example,the computing system 150 may use both the intersection point and thefarthest point from the (e.g., nozzle of the) welding-type tool 110together to estimate the welding location(s).

In some examples, the weld tracking process 400 may additionally, oralternatively, determine one or more weld quality parameters and/or welddefects at block 410. In some examples, the weld quality parameterand/or weld defect determination(s) may be based on the position(s)and/or orientation(s) of the welding-type tool 110 and/or arc 112determined at block 408. In some examples, the weld quality parameterand/or weld defect determination(s) may be further based onposition/orientation information about the workpiece(s) 106 and/orcalibration information provided at block 402. Examples of weld qualityparameters may include penetration depth, weld length, and porosity.Examples of weld defects may include cracks, undercut, excessiveporosity, excessively deep/shallow penetration, burn through, lack offusion, voids, spatter, irregular weld shape, spatter and whiskers.

In the example of FIG. 4, the weld tracking process 400 proceeds toblock 412 after block 410. At block 412, the weld tracking process 400determines feedback for, and/or provides feedback to, the operator 104.In some examples, the determination at block 412 may be based on thewelding technique parameters, welding operation parameters, weld qualityparameters, and/or weld defects determined at block 410, as well ascertain expected weld technique parameters, welding operationparameters, weld quality parameters, and/or other target criteria. Insome examples, the weld tracking process 400 may also determine and/oroutput other information, such as, for example, a score (e.g.,numerical, grade, pass/fail, etc.), based on the determined/expectedwelding technique parameters, welding operation parameters, weld qualityparameters, weld defects, and/or other target criteria. In someexamples, the weld tracking process 400 may also output thedetermined/expected welding technique parameters, welding operationparameters, weld quality parameters, weld defects, and/or other targetcriteria.

In some examples, the expected weld technique parameters (and/or weldquality parameters) may be optimal/target values (and/or ranges ofvalues) of the weld technique parameters (and/or weld qualityparameters) in general, or for each joint, weld, and/or welding-typeoperation. In some examples, the target criteria may be additionaloptimal/target values and/or ranges of values related to thewelding-type operation (e.g., location of the welding-type operation(s),duration of the welding-type operation(s), order of welding-typeoperations, etc.).

In some examples, the expected weld technique parameters, expectedwelding operation parameters, expected weld quality parameters, and/ortarget criteria may be determined and/or provided by a weld monitoringsystem. In some examples, the expected weld technique parameters,expected welding operation parameters, expected weld quality parameters,and/or target criteria may be adjusted by the operator 104 (e.g., viathe UI 151 and/or I/O device(s) 208). In some examples, the expectedweld technique parameters, expected welding operation parameters,expected weld quality parameters, and/or target criteria may bedetermined dynamically based on welding parameters of (and/orcommunicated from) the welding-type equipment 116.

In some examples, the expected weld technique parameters, expectedwelding operation parameters, expected weld quality parameters, and/ortarget criteria may be determined dynamically based on theposition/location of the weld relative to previous weld(s) and/or withinthe welding environment. In some examples, other (e.g., job, work order,WPS, project, etc.) information may be determined dynamically based onthe position/location of the weld relative to previous weld(s) and/orwithin the welding environment (i.e., the welding operationparameter(s)). In some examples, the expected weld technique parameters,expected welding operation parameters, expected weld quality parameters,and/or target criteria may be determined using sample data from expertwelders. In some examples, the expected weld technique parameters,expected welding operation parameters, expected weld quality parameters,and/or target criteria may be determined based on machine learningalgorithms.

In some examples, the feedback output at block 412 may be provided viathe UI 151, operator interface 130, lens assembly 206, and/or I/Odevice(s) 208. In some examples, the feedback may be audio, visual,and/or haptic. In some examples, the weld tracking process 400 mayprovide feedback via the welding-type tool 110 (e.g., via one or moresignals commanding a device in the welding-type tool 110 to providevisual, audio, and/or haptic output). In some examples where thefeedback is visual, the feedback may be in the form of guides, arrows,lines, text, pictures, graphics, animations, videos, shapes, and/orother appropriate imagery. In some examples, feedback may be formattedwith different colors, patterns, presentation styles (e.g., static,blinking, scrolling, etc.) to express different meanings. In someexamples, the feedback may be displayed to one eye (monoscopic), botheyes (stereoscopic), and/or shown in peripheral portions of a displayscreen 504 to avoid distracting the operator 104. In some examples, thejoint/weld path highlight 506 discussed above may be consideredfeedback. In some examples, even without the aforementioned calibration,the weld tracking process 400 may predict the joint/weld path after awelding-type operation has begun, and show a similar highlight 506 asfeedback.

FIG. 6 shows an example of how visual feedback 602 might be depicted tothe operator 104 on a display screen 504 (e.g., of the UI 151, lensassembly 206, operator interface, and/or I/O device(s) 208). As shown,some of the feedback 602 is provided overlaid on a portion of thewelding-type tool 110. In some examples, the welding-type tool 110 shownmay be the actual welding-type tool seen through a cover lens, or adisplayed representation of the real welding-type tool 110. In someexamples, the feedback 602 may be shown separate from the welding-typetool 110.

In the example of FIG. 6, the feedback 602 is presented in the form ofarrow feedback 602 a, slider feedback 602 b, arch feedback 602 c,reticle feedback 602 d, and marker feedback 602 e. In some examples, thearrow feedback 602 a may be used to provide feedback to the operator 104regarding the travel speed of the welding-type tool 110 and/or otherwelding technique parameters. In some examples, the slider feedback 602b may be used to provide feedback to the operator 104 regarding thecontact to tip distance of the welding-type tool 110 and/or otherwelding technique parameters. In some examples, the arch feedback 602 cmay be used to provide feedback to the operator 104 regarding the workangle and/or travel angle of the welding-type tool 110, and/or otherwelding technique parameters.

In some examples, the reticle feedback 602 d may be used to providefeedback to the operator 104 regarding welding location(s). In theexample of FIG. 6, two feedback reticles 602 d are shown, indicating twodifferent welding locations (e.g., corresponding to two different weldsin an expected weld sequence). In some examples, the marker feedback 602e may be used to provide feedback to the operator 104 regarding whichwelding location is next in the expected weld sequence. While only onefeedback marker 602 e is shown in the example of FIG. 6, in someexamples, multiple markers 602 e may be used with different effects(e.g., colors, transparency, numbering, text etc.) to indicate whether awelding location corresponds to the next weld, a past weld, a particularnumber weld, and/or other information. In some examples, reticlefeedback 602 d may be combined with arrow feedback 602 a to indicate adirection in which the operator 104 should move the welding-type tool110 to reach the target welding location of the next weld.

In some examples, more or fewer feedback 602 may be presented. In someexamples, the color, effects, and/or presentation style of the feedbackmay be altered to emphasize certain feedback 602 (e.g., to indicatesubstantial deviation of the corresponding welding technique, location,and/or sequence parameter(s) from what is expected).

In the example of FIG. 4, the weld tracking process 400 proceeds toblock 414 after block 412. At block 414, the weld tracking process 400determines whether the difference between one or more of the determinedparameters and one or more of the corresponding expected parametersexceed one or more thresholds. In some examples, the thresholds may bestored in memory, received from the monitoring system, automaticallydetermined by the weld tracking process 400 (e.g., based on the targetcriteria), and/or entered by the operator 104 (e.g., via the UI 151,operator interface 130, and/or I/O device(s) 208).

In the example of FIG. 4, the weld tracking process 400 ends (or, insome examples, returns to block 402 or 404) if the difference(s) areless than the threshold(s) (e.g., for all or at least a threshold numberof parameters). If the difference(s) are less than the threshold(s)(e.g., for all or at least a threshold number of parameters), the weldtracking process 400 proceeds to block 416. In some examples, the weldtracking process 400 may skip block 414 and proceed to block 416regardless.

At block 416, the weld tracking process 400 sets and/or adjusts one ormore welding parameters of the welding-type equipment 116 to compensatefor deviations between the expected and determined parameters. In someexamples, the weld tracking process 400 may determine whatsettings/adjustments are appropriate (if any) and send one or moresignals to the welding-type equipment 116 representative of one or morecommands to adjust the welding parameter(s) to a commanded degree.Thereafter, the welding-type equipment 116 may implement the commandedsettings/adjustments.

In some examples, the weld tracking process 400 may send one or moresignals to the welding-type equipment 116 representative of the targetcriteria, determined welding technique/operation/quality parameters,expected welding technique/operation/quality parameters, and/ordifferences therebetween. Thereafter, the welding-type equipment 116 mayitself determine what settings/adjustments (if any) are appropriate, andimplement those settings/adjustments. In some examples, the weldingparameters and/or values to use in the settings/adjustments may bedetermined based on, for example, the position/orientation of thewelding-type tool 110 and/or arc 112, target criteria, determinedwelding technique/operation/quality parameters, expected weldingtechnique/operation/quality parameters, and/or differences therebetween.

In some examples, the welding-type equipment 116 (and/or welding-typetool 110) may be disabled entirely if a threshold number of theparameters are above some threshold deviation. In some examples, thewelding-type equipment 116 (and/or welding-type tool 110) may also bedisabled if the position/orientation of the welding-type tool 110 and/orarc 112 has a position/orientation that is more than a thresholddistance away from an expected welding position. In some examples, thewelding-type equipment 116 (and/or welding-type tool 110) may bere-enabled if the welding-type tool 110 and/or arc 112 moves back withina threshold distance away from the expected welding position. As shown,the weld tracking process 400 ends after block 416 (though, in someexamples, the weld tracking process 400 may instead return to block 402or block 404).

In some examples, the disclosed welding helmet 200 may provide acompact, independent, and/or mobile weld tracking system. This mobileweld tracking system may allow for weld tracking outside of the normallyfixed bounds of the weld tracking system 100. In some examples, thewelding helmet 200 may track its own position and/or orientationrelative to a reference point in a welding environment, as well as theposition and/or orientation of a welding-type tool 110 and/or arc 112relative to the helmet. In this way, the welding helmet 200 candifferentiate between movement of the welding helmet 200 and movement ofthe tool 110 and/or arc 112. By tracking movement of the tool 110 and/orarc 112 the weld tracking system can analyze the welding technique of anoperator 104, as well as weld quality, welding location, and/or weldsequence. In cases where the weld tracking data, welding technique, weldquality, welding location, and/or weld sequence deviates from what isexpected, the welding helmet 200 may offer corrective feedback, changewelding parameters to compensate, and/or disable welding-type operationsentirely. In some examples, the weld tracking system 100 and/or weldinghelmet 200 may be calibrated using the welding-type tool 110 (and/orcalibration tool 132) to provide more robust performance.

The present methods and/or systems may be realized in hardware,software, or a combination of hardware and software. The present methodsand/or systems may be realized in a centralized fashion in at least onecomputing system, or in a distributed fashion where different elementsare spread across several interconnected computing or cloud systems. Anykind of computing system or other apparatus adapted for carrying out themethods described herein is suited. A typical combination of hardwareand software may be a general-purpose computing system with a program orother code that, when being loaded and executed, controls the computingsystem such that it carries out the methods described herein. Anothertypical implementation may comprise an application specific integratedcircuit or chip. Some implementations may comprise a non-transitorymachine-readable (e.g., computer readable) medium (e.g., FLASH drive,optical disk, magnetic storage disk, or the like) having stored thereonone or more lines of code executable by a machine, thereby causing themachine to perform processes as described herein.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. Therefore, it is intendedthat the present method and/or system not be limited to the particularimplementations disclosed, but that the present method and/or systemwill include all implementations falling within the scope of theappended claims.

As used herein, “and/or” means any one or more of the items in the listjoined by “and/or”. As an example, “x and/or y” means any element of thethree-element set {(x), (y), (x, y)}. In other words, “x and/or y” means“one or both of x and y”. As another example, “x, y, and/or z” means anyelement of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z),(x, y, z)}. In other words, “x, y and/or z” means “one or more of x, yand z”.

As utilized herein, the terms “e.g.,” and “for example” set off lists ofone or more non-limiting examples, instances, or illustrations.

As used herein, the terms “coupled,” “coupled to,” and “coupled with,”each mean a structural and/or electrical connection, whether attached,affixed, connected, joined, fastened, linked, and/or otherwise secured.As used herein, the term “attach” means to affix, couple, connect, join,fasten, link, and/or otherwise secure. As used herein, the term“connect” means to attach, affix, couple, join, fasten, link, and/orotherwise secure.

As used herein the terms “circuits” and “circuitry” refer to physicalelectronic components (i.e., hardware) and any software and/or firmware(“code”) which may configure the hardware, be executed by the hardware,and or otherwise be associated with the hardware. As used herein, forexample, a particular processor and memory may comprise a first“circuit” when executing a first one or more lines of code and maycomprise a second “circuit” when executing a second one or more lines ofcode. As utilized herein, circuitry is “operable” and/or “configured” toperform a function whenever the circuitry comprises the necessaryhardware and/or code (if any is necessary) to perform the function,regardless of whether performance of the function is disabled or enabled(e.g., by a user-configurable setting, factory trim, etc.).

As used herein, a control circuit may include digital and/or analogcircuitry, discrete and/or integrated circuitry, microprocessors, DSPs,etc., software, hardware and/or firmware, located on one or more boards,that form part or all of a controller, and/or are used to control awelding process, and/or a device such as a power source or wire feeder.

As used herein, the term “processor” means processing devices,apparatus, programs, circuits, components, systems, and subsystems,whether implemented in hardware, tangibly embodied software, or both,and whether or not it is programmable. The term “processor” as usedherein includes, but is not limited to, one or more computing devices,hardwired circuits, signal-modifying devices and systems, devices andmachines for controlling systems, central processing units, programmabledevices and systems, field-programmable gate arrays,application-specific integrated circuits, systems on a chip, systemscomprising discrete elements and/or circuits, state machines, virtualmachines, data processors, processing facilities, and combinations ofany of the foregoing. The processor may be, for example, any type ofgeneral purpose microprocessor or microcontroller, a digital signalprocessing (DSP) processor, an application-specific integrated circuit(ASIC), a graphic processing unit (GPU), a reduced instruction setcomputer (RISC) processor with an advanced RISC machine (ARM) core, etc.The processor may be coupled to, and/or integrated with a memory device.

As used, herein, the term “memory” and/or “memory device” means computerhardware or circuitry to store information for use by a processor and/orother digital device. The memory and/or memory device can be anysuitable type of computer memory or any other type of electronic storagemedium, such as, for example, read-only memory (ROM), random accessmemory (RAM), cache memory, compact disc read-only memory (CDROM),electro-optical memory, magneto-optical memory, programmable read-onlymemory (PROM), erasable programmable read-only memory (EPROM),electrically-erasable programmable read-only memory (EEPROM), acomputer-readable medium, or the like. Memory can include, for example,a non-transitory memory, a non-transitory processor readable medium, anon-transitory computer readable medium, non-volatile memory, dynamicRAM (DRAM), volatile memory, ferroelectric RAM (FRAM),first-in-first-out (FIFO) memory, last-in-first-out (LIFO) memory, stackmemory, non-volatile RAM (NVRAM), static RAM (SRAM), a cache, a buffer,a semiconductor memory, a magnetic memory, an optical memory, a flashmemory, a flash card, a compact flash card, memory cards, secure digitalmemory cards, a microcard, a minicard, an expansion card, a smart card,a memory stick, a multimedia card, a picture card, flash storage, asubscriber identity module (SIM) card, a hard drive (HDD), a solid statedrive (SSD), etc. The memory can be configured to store code,instructions, applications, software, firmware and/or data, and may beexternal, internal, or both with respect to the processor.

The term “power” is used throughout this specification for convenience,but also includes related measures such as energy, current, voltage, andenthalpy. For example, controlling “power” may involve controllingvoltage, current, energy, and/or enthalpy, and/or controlling based on“power” may involve controlling based on voltage, current, energy,and/or enthalpy.

As used herein, welding-type refers to welding (including laser weldingand/or hot wire welding), cladding (including laser cladding), brazing,plasma cutting, induction heating, carbon arc cutting or gouging, hotwire preheating, and/or resistive preheating.

As used herein, a welding-type tool refers to a tool suitable for and/orcapable of welding (including laser welding and/or hot wire welding),cladding (including laser cladding), brazing, plasma cutting, inductionheating, carbon arc cutting or gouging, hot wire preheating, and/orresistive preheating.

As used herein, welding-type power refers to power suitable for welding(including laser welding and/or hot wire welding), cladding (includinglaser cladding), brazing, plasma cutting, induction heating, carbon arccutting or gouging, hot wire preheating, and/or resistive preheating.

As used herein, a welding-type power supply and/or welding-type powersource refers to a device capable of, when input power is appliedthereto, supplying output power suitable for welding (including laserwelding and/or hot wire welding), cladding (including laser cladding),brazing, plasma cutting, induction heating, carbon arc cutting orgouging, hot wire preheating, and/or resistive preheating; including butnot limited to transformer-rectifiers, inverters, converters, resonantpower supplies, quasi-resonant power supplies, switch-mode powersupplies, etc., as well as control circuitry and other ancillarycircuitry associated therewith.

As used herein, disable may mean deactivate, incapacitate, and/or makeinoperative. As used herein, enable may mean activate and/or makeoperational.

Disabling of circuitry, actuators, and/or other hardware may be done viahardware, software (including firmware), or a combination of hardwareand software, and may include physical disconnection, de-energization,and/or a software control that restricts commands from being implementedto activate the circuitry, actuators, and/or other hardware. Similarly,enabling of circuitry, actuators, and/or other hardware may be done viahardware, software (including firmware), or a combination of hardwareand software, using the same mechanisms used for disabling.

What is claimed is:
 1. A weld tracking system, comprising: a sensorsystem configured to capture sensor data pertaining to a weldingenvironment; and control circuitry configured to: track a torch positionof a welding-type torch based on the sensor data, track a tool positionof a calibration tool based on the sensor data, identify a firstendpoint based on the tool position when the calibration tool isactivated, identify a second endpoint based on the torch position whenwelding is initiated via the welding-type torch, and identify a weldpath based on the first endpoint and the second endpoint.
 2. The weldtracking system of claim 1, wherein the control circuitry is configuredto identify the weld path as comprising a path between the firstendpoint and the second endpoint.
 3. The weld tracking system of claim1, wherein the control circuitry is configured to identify the weld pathas comprising the shortest path between the first endpoint and thesecond endpoint.
 4. The weld tracking system of claim 1, wherein thecontrol circuitry is configured to identify the weld path as comprisinga line between the first endpoint and the second endpoint.
 5. The weldtracking system of claim 1, wherein the calibration tool comprises thewelding-type torch.
 6. The weld tracking system of claim 1, whereinwelding is initiated via the welding-type torch when the welding-typetorch performs a tack weld.
 7. The weld tracking system of claim 1,wherein the control circuitry is configured to identify the secondwelding point based on the torch position when welding is initiated viathe welding-type torch for less than one second.
 8. The weld trackingsystem of claim 1, wherein the control circuitry is configured to:identify an intermediate point based on the tool position when thecalibration tool is activated or the torch position when welding isinitiated via the welding-type torch, and identify the weld path basedon the first endpoint, the intermediate point, and the second endpoint.9. The weld tracking system of claim 8, wherein the control circuitry isconfigured to identify the weld path as comprising a path between thefirst endpoint and the second endpoint that also intersects theintermediate point.
 10. The weld tracking system of claim 1, furthercomprising a display screen configured to display a representation ofthe weld path.
 11. A weld tracking system, comprising: a sensor systemconfigured to capture sensor data pertaining to a welding environment;and processing circuitry; and memory circuitry comprising machinereadable instructions which, when executed by the processing circuitry,cause the processing circuitry to: track a torch position of awelding-type torch based on the sensor data, track a tool position of acalibration tool based on the sensor data, identify a first endpointbased on the tool position when the calibration tool is activated,identify a second endpoint based on the torch position when welding isinitiated via the welding-type torch, and identify a weld path based onthe first endpoint and the second endpoint.
 12. The weld tracking systemof claim 11, wherein the memory circuitry comprises machine readableinstructions which, when executed by the processing circuitry, cause theprocessing circuitry to identify the weld path as comprising a pathbetween the first endpoint and the second endpoint.
 13. The weldtracking system of claim 11, wherein the memory circuitry comprisesmachine readable instructions which, when executed by the processingcircuitry, cause the processing circuitry to identify the weld path ascomprising the shortest path between the first endpoint and the secondendpoint.
 14. The weld tracking system of claim 11, wherein the memorycircuitry comprises machine readable instructions which, when executedby the processing circuitry, cause the processing circuitry to identifythe weld path as comprising a line between the first endpoint and thesecond endpoint.
 15. The weld tracking system of claim 11, wherein thecalibration tool comprises the welding-type torch.
 16. The weld trackingsystem of claim 11, wherein welding is initiated via the welding-typetorch when the welding-type torch performs a tack weld.
 17. The weldtracking system of claim 11, wherein the memory circuitry comprisesmachine readable instructions which, when executed by the processingcircuitry, cause the processing circuitry to identify the second weldingpoint based on the torch position when welding is initiated via thewelding-type torch for less than one second.
 18. The weld trackingsystem of claim 11, wherein the memory circuitry comprises machinereadable instructions which, when executed by the processing circuitry,cause the processing circuitry to: identify an intermediate point basedon the tool position when the calibration tool is activated or the torchposition when welding is initiated via the welding-type torch, andidentify the weld path based on the first endpoint, the intermediatepoint, and the second endpoint.
 19. The weld tracking system of claim18, wherein the memory circuitry comprises machine readable instructionswhich, when executed by the processing circuitry, cause the processingcircuitry to identify the weld path as comprising a path between thefirst endpoint and the second endpoint that also intersects theintermediate point.
 20. The weld tracking system of claim 11, furthercomprising a display screen configured to display a representation ofthe weld path.